A+ Green Guide rated weber.pral D by Saint-Gobain Weber has been spray applied to the interior walls of the three-storey Bastion Gate which has an imposing portcullis entrance, high arched ceilings and fine, intricate detail work. This through-coloured render incorporates innovative One-Coat Technology which is recognised for its contribution to minimising programme works. By reducing the drying time associated with a traditional two coat system by as much as 50%, on-site labour and the cost of equipment is greatly reduced which has helped with the demanding completion schedule of the Bastion Gate.

Saint-Gobain Weber is the first producer of monocouche renders to be awarded an A+ rating as defined in the BRE Global 2008 Green Guide to Specification. These audited materials help specifiers to make selections that will collectively reduce the environmental impact of their buildings.

Main contractor Samuel Millar, of Randalstown, County Antrim, has undertaken the interior refurbishment of the walls and ceilings in just five months. Sam Millar, managing director, comments: "This has been a really labour intensive project but it looks magnificent and my applicators are very proud of the finish we have achieved. We normally work on new, modern buildings where dimensions are true and walls are straight so this has been a challenging project." 

"Everything about this render is perfect for us - it's quick and easy to apply, suitable for spray application, and achieves a perfect finish. Just brilliant, we can't fault it," says Michael Martin, render applicator, Millar Construction. "We've used other brands but they are unworkable by comparison and couldn't have been used in this specialist application, especially on the ceilings." In the Bastion Gate, authentic colours of Chalk, Sand, Earth Red and Stone Grey have been used to replicate the original colour schemes in the principal rooms which have recaptured the bright atmosphere of the Castle in its prime.

Leading London architect Thomas Hopper was commissioned to create Gosford Castle in 1819. This family home, which has 197 rooms, took 20 years to complete and was designed in the Norman Revival style. The castle walls are finished in granite while pink marble was designed into much of the interior. Local masters were responsible for the construction of the marble columns; local craftsmen and materials were employed for the wood panelling and carvings; the vaulted ceilings were picked out with gold paint and Italian plasterers created many of the magnificent ceilings. 

Gosford Castle has seen a variety of uses over its lifetime, from a military billet to the winter base of a travelling circus. It remained derelict until 2006 when it was rescued by a local businessman who, with specialist architects and the Northern Ireland Heritage Service, saved the fabric of the building restoring it to its former glory. 

Saint-Gobain Weber's renders are manufactured in Bedfordshire and Shropshire providing local manufacture, while reduced transportation mileage and CO² emissions contribute to the company's sustainability and environmental policies. 

In the construction industry, time is money so why wait unnecessarily on site when the improved weber.therm XP, with innovative technology that allows the product to work in harmony with seasonal conditions, can save valuable time by minimising the installation schedule. This development allows contractors to scrape the render to a same day finish in the summer and achieve a next day finish in the winter, resulting in shorter programme periods, fewer on-site hours and allowing faster access to other trades. 

Saint-Gobain Weber have also taken the opportunity to improve the algae resistance of the product and make weber.therm M1 even easier to apply by machine or hand. "We have worked with our applicators to maximise efficiency on site with stunning effects," says James Mead, Head of Product Management. "These innovative changes really do reiterate why weber.therm XP is a market leading EWI system. The specifier, contractor or client, can confidently choose weber.therm XP for use in new build and refurbishment schemes regardless of size, height or exposure. This is due to the system's exceptional thermal performance, impact resistance and wind-loading capabilities, and now the improved formulation means that less time is spent on site, especially during adverse weather conditions." 

weber.therm XP's unique system uses a specially designed one-coat, through-colour mineral render which speeds up application and significantly reduces on-site labour and associated access costs. The new render formulation with innovative technology continues to improve this feature, reducing waiting time on site. While this high performance system is capable of improving thermal efficiency with U-values well below the 0.3W/m²K standard, contributing to reduced energy consumption and CO2 emissions, the system is responsible for substantial improvement in the aesthetics of Britain's aging housing stock. The system extends the life of existing buildings, especially so-called hard-to-treat properties, by keeping the old structure warm and stable. 

weber.therm XP is a layered system which is quick and easy to install. The insulant is applied in the appropriate thickness to meet the specified U-value, which Saint-Gobain Weber's technical team will calculate for you. This is mechanically fixed to a sound substrate with high strength, thermal-break fixings and finished with weber.therm M1 render, containing mesh-cloth reinforcement, in a variety of colours and textures. The weber.therm XP EWI system is further supported by BBA Certification offering peace of mind to the architect, contractor and tenant. 

Saint-Gobain Weber offers a comprehensive package of Technical Support Services and can advise on the most appropriate weber.therm EWI system for a project, provide U-value and condensation risk analysis, and offer a full Site Application Guide outlining every stage of the process, as well as on-site inspection. Saint-Gobain Weber can also recommend applicators from a nationwide register of trained installers. Both social and private landlords may be eligible for government funding support and Saint-Gobain Weber can assist in this process by helping with the administration associated with applying for and securing funding. 

DOWNLOAD THE NEW WEBER.APP 

Targeting specifiers, main contractors, applicators and fixers, the weber.app provides instant access to comprehensive product information - from NSAI accredited external wall insulation to BRE A+ Green Guide approved Monocouche renders, inspirational case studies on architecturally specified floor screeds, innovative concrete repair systems and tile prep and fix technologies. 

With an easy-to-use intuitive interface the weber.app offers time saving functionality that includes technical data, product features and benefits across the entire Saint-Gobain Weber product range as well as a useful Consumption Calculator facility and Find a Stockist function. A helpful Problem Solutions section provides practical and helpful advice for busy professionals and tradesmen while YouTube hosted "How To" videos illustrate the practical application and best use of Saint-Gobain Weber products and materials, technologies and systems. A calendar facility can also be used to remind users of the latest trade shows, exhibitions and events throughout the year as well as a news feed of case studies and projects.

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Using modern architectural images, captioned with client, architect and installer details together with a wide range of colour, texture and decorative finishes illustrate how new-build and retrofit projects can achieve powerful and dynamic aesthetics in the use of render on the façade. 

This guide has been designed to inspire you - our customer - with the use photographic case studies which focus on the exceptional quality and finish of Weber render solutions.  The guide highlights how the best use of our extensive range of systems will contribute to the visual drama and aesthetics of the many stunning buildings in our project portfolio.  Sympathetic colours from a vast pallet of shades complement existing and new neighbourhood landscapes while interesting finishes provide essential variety. 

Snap shot information about these inspiring projects have been given detailing the problems faced and overcome with Weber’s extensive product range and approved installer network

The accompanying Weber Render Solutions Technical guide is currently being updated and is due for publication later this year which will provide guidance on the correct technical solution for specific applications.

The Millionaire Club award is made to a Saint-Gobain manufacturing site which has achieved a 1,000,000 man-hours record with no lost-time accident or, dependent on plant size and in this case Ballyclare is a relatively small site, a five-year period without a lost-time accident.  

Going forward, Ballyclare is on schedule to successfully achieve a five-year incident-free period in which neither lost time or medical treatment – such as stitches where the employee returns to normal duties without lost time – has been incurred.  

“The key to this achievement and Ballyclare’s excellent safety record is through improvement of basic conditions,” says Liam Campbell, “but even more important is the behavioural safety programme.  Most accidents are caused by the actions of the person injured, or those of a colleague, and it is in these attitudes and responsibilities we have seen such improvement.”  

Saint-Gobain Weber’s Ballyclare site received a Diamond award in 2009 in acknowledgement of a significant improvement in Health & Safety systems and standards, in team behaviour and spirit, and a good knowledge of legislation.  The achievement is based on a 20-Step internal audit which is conducted at every Saint-Gobain manufacturing site. Collectively these procedures ensure a safer and more comfortable working environment for employees and visitors.

“The Millionaire Club award is one more step to ensuring that everyone at the Ballyclare site goes home at the end of the day in the same good condition they arrived in,” states Campbell.

The small cavity in the wall construction has been filled with blown insulation whilst the interior space has been maintained by adding solid insulation externally.  This has been thoroughly protected with Saint-Gobain Weber’s technical render system which also provides a classic red brick finish to match the newly renovated building with adjacent properties.

At Damer Court striking results have been achieved with the use of the versatile weber.rend RB system. It produces a superb brick finish in just a fraction of the time, and cost, of full brickwork cladding.  weber.rend RB is the combination of two polymer modified mortars used in conjunction to create a brickwork pattern.

Damer Court provides homes for those in need and runs 52 metres along Upper Wellington Street, Dublin.  The NSAI approved installer Active Thermal Building Services of Dublin, was appointed to carry out the project which included the weber.therm XB EWI application, replacement windows and doors and attic insulation. Francis Ahern, General Manager of Active Thermal, was the ETIC supervisor on the project from its commencement.

“Damer has always been a well recognised building and the weber.therm EWI system has given it a new lease of life. The homes are now well above the required Part L Building Regulations and the external finish is a perfect fit for the locality. We are proud of this job and the residents are delighted with the dramatic improvement in comfort levels. Their heating systems have not been running since April and the reduction in heating bills is becoming evident when compared to previous years,” reports Mr Ahern.

The five-month programme of renovations undertaken by Active Thermal saw 80mm of EPS insulation fixed to all external walling. Window apertures were brought out to maintain the correct reveal depths. Mechanical fixings hold the insulation in place. The brick-effect is achieved by first applying 7-8mm of weber.rend RBB polymer modified mortar in the desired colour and when this has “taken up”, a 2-3mm coating of weber.rend RBF in the selected face finish colour is applied. Experience and weather conditions will determine the moment that the outer coating can be “scribed” to expose the base coating in the chosen brickwork pattern. At Damer Court the accurate, sharp lines are testament to the skills applied.

The Award recognises the improvements in Health & Safety systems at the Ballyclare site and is testimony to the hard work and commitment of the team over recent years.  The site has been regularly audited for its safety systems, for team behaviour and team spirit, and knowledge of Health & Safety legislation which ensures a safer and more comfortable working environment for the employees.  

The Award, which was collected by Plant Manager Liam Campbell at an Awards ceremony in Paris by Pierre-Andre de Chalendar, Saint-Gobain CEO, comments:

“This Diamond is one more step forward in making sure that everyone at Ballyclare goes back home at the end of the day in the same condition he or she arrived in.  The appearance of the site alone compared to three years ago speaks volumes and every member of the team is acutely aware of how greatly improved our location now is.”  

The team will now focus on continuous improvement to ensure these standards are maintained for the benefit of everyone.  

Image: Liam Campbell, Plant Manager, Weber, Ballyclare site, is presented the award by Pierre-Andre de Chalendar, Saint-Gobain, CEO  

In the modernisation of Peterborough’s 1950’s homes, originally constructed to house evacuated Londoner’s which were, at that time, labelled ‘temporary’, are now receiving a total facelift.  Some 60 years later, a major refurbishment project is underway to bring these Cross Keys Homes closer to today’s standard of thermal performance.  A key factor in this plan is the use of the weber.therm External Wall Insulation (EWI) system.  

Nearly 600 homes are undergoing improvements by housing association Cross Keys Homes in a multi-million pound project that has benefited from £1m of support secured by Weber from the CERT funding initiative.  Main contractor Mears has renewed roofs, fascias and soffits with specialist applicators, Retrofit Limited and Lawtec Limited, handling the £3.73 million weber.therm External Wall Insulation (EWI) system installation.  

Here a variety of different finishes are being used with the versatile weber.therm EWI system to allow properties to keep their original character while achieving visual variety.  To date, and over several phases, this has included weber.therm XM which uses through coloured, decorative and weather resistant render to the insulation system while other properties have been finished with a real brick appearance in weber.therm RB.  

Striking results have been achieved using weber.rend RB which produces a superb brick look-alike finish in just a fraction of the time and at a fraction of the cost of full brickwork cladding. weber.rend RB is the combination of two polymer modified mortars used in conjunction to create the brick work pattern.  Alternatively, a real brick finish is available from Weber and can be achieved using weber.therm XB.  

Insulation is fixed to the original substrate of the building followed by a basecoat render with meshcloth reinforcement. Once set, the surface is lightly comb scratched prior to the application of the weber.rend RBB render coat which acts as the “mortar” joint and is available in eight different colours.

When the RBB coat has “taken-up” and is firm enough to allow application of the face coat, 2–3mm of weber.rend RBF is applied and stippled with a soft bristle brush to give the “brick” effect finish. Eight different colours of face render are available, allowing the client to replicate almost any brick and mortar combination which is particularly important when matching in with existing properties.  

The brick pattern is achieved by cutting through the weber.rend RBF face coat to expose the contrasting RBB render thus creating the attractive brick pattern finish. What’s neat about the system is that any brick pattern can be achieved including conventional ‘cavity’ layout as well as ‘header and stretcher’ bonding of traditional solid walls. Correctly applied this system is often mistaken for high quality bricklaying - even by experienced tradesmen!  

The weber.rend RB brick effect render system, used as part of the weber.therm XM EWI system, is transforming both the aesthetics and thermal efficiency of non-traditional and solid wall homes in Peterborough.  

The dramatic changes to the aesthetics of these Peterborough homes are matched by the changes in performance.  Householders report new levels of warmth and comfort.  The original prefabricated steel shell bungalows on Welland Close for example had no insulation at all other than the plaster board lining for the room interiors.  In winter the steel is ice cold and in summer heat radiates off the metal internally making this one of the most uncomfortable construction methods ever.  Residents are now reporting that not only are their homes much quieter inside but the properties are far warmer, contributing dramatically to reduced heating costs in winter, while aesthetically they have changed beyond compare.

Of the seven new build primaries, two secondries and a refurbished primary school, six of the buildings are now complete.  A multinational team of contractors and design professionals – from Scotland, England, Denmark and Iceland – has been boosted by a council grant to allow work to continue on the construction of the initial sites.  A further three will be handed over this summer.  

These timber framed buildings have been designed with Scandinavian standards of insulation, lighting management systems, underfloor heating, natural ventilation and rainwater conservation systems and reach BREEAM ‘excellent’ standards using the 2006 benchmark for schools.  

Lead contractor Pihl UK Ltd., a successful international contractor, draws on its Scandinavian heritage and provides a unique blend of innovative, environmentally friendly and modern techniques.  The weber.rend MT system comprises a range of products for application onto a panel background or masonry substrates, where a high level of crack resistance is required. The construction of the external façade in this case incorporated a panel background, which resulted in weber.rend LAC, Lightweight Adhesive Coat, being used in conjunction with a glass fibre meshcloth and a synthetic finish. The system is ideal for fast track construction and ensures the timber is kept in a stable, dry environment giving good impact resistance and weather protection.

weber.plast TF150, an acrylic based, decorative finish, has been used as the final finish coat in white.  It is a wet pre-mixed material, factory batched for consistency, and ready to use and apply to prepared surfaces on to the tinted primer.  weber.plast TF150 provides a durable and resilient finish and is a robust and excellent all-round weather performer.

Contractor George Rome (Glasgow) Limited, a multi-disciplined contractor with a particular focus on the most technologically advanced render and plastering systems, has been the applicator on this extensive project.

Weber Leca® Insulation Fill is a lightweight clay material formed by heating and firing natural glacial clays which transforms it into various sized lightweight ceramic granules.  These granules have a hard ceramic shell and are treated to stop them absorbing moisture. In this form the material has first class insulation properties. The high volume by weight is ideal for most infill operations.  

The properties in St Helens, constructed in the 1950’s, were built on poor, uneven and unstable ground. Substantial digging had to be undertaken at the time of construction to enable foundations to be laid as well as equally substantial brick foundations until stable ground was achieved. The old style timber joists and floorboards were therefore laid across voids up to two metres deep in some places.  

Over time these timbers have rotted and the renovation project has had to remedy the void to enable insulated solid floors to be created. Traditional hardcore fill would have had to be barrowed into place as access is restricted. Four men would have been employed for two weeks on each property to fill these voids prior to the concrete floor being laid.  

The Weber Leca® Insulation Fill was brought to the site in a 55m³ load on a truck with blower system which pneumatically delivers the lightweight fill. One operator controls the flow from the delivery pipe and another rakes the insulation fill into position. The loose aggregate is poured in 500mm deep layers and a vibrating plate compactor is run over the fill to firm it into position. In just 60 minutes the Weber Leca® Insulation Fill has filled the deepest voids; lesser voids in this project have taken no more than 15 minutes to fill.  A 1200 gauge polythene membrane is then applied to the filled void before a steel mesh is installed in preparation for the pumped concrete.

Dave Williams, site project manager for Helena Partnership, says: “We have saved thousands of pounds just in labour costs by using Weber Leca® Insulation Fill. It is quick, clean and easily handled. It provides great insulation - we just put a damp proof membrane over the Weber Leca® Insulation Fill and lay the concrete. The whole renovation job now takes just a few days so the householder is less inconvenienced and doesn’t have to move out of the property for the two or three weeks that it would take if we had used traditional methods.”  

Dave continues: “I’ll never again use another piece of rubble to fill a void. Weber Leca® Insulation Fill has proved a brilliant solution for us.”

Both products are one-coat, through-coloured monocouche renders manufactured from carefully selected raw materials.  They achieve an excellent weather resistant, low maintenance and highly durable finish, and while providing a protective outer coat for the building will, at the same time, allow the structure to breathe.  These renders are quick and easy to apply, contributing to short programme periods which reduce associated scaffolding and site costs and encourage the completion of ground works at an earlier stage.  

The Green Guide is an accredited environmental profile rating system for products and building elements.  By auditing materials and components on their environmental performance and impact, and the way they are used in buildings, specifiers and designers can consider comparable systems, or materials, and make selections that will collectively reduce the environmental impact of their buildings.  This will help to meet the mandatory requirements and achieve more materials credits in a Code for Sustainable Homes (CSH) assessment.  

These profile ratings measure the performance of materials over their entire life based on Life Cycle Assessments (LCA), measuring the material from extraction and harvesting, process manufacturing, construction and maintenance methods, through to its eventual disposal.  Information on key issues related to environmental sustainability also contribute to the Ecopoints assessment – the lower the Ecopoints the less environmental impact the product or system will have.  

Comments Steve Belcher, Product Manager – Weber: “The achievement of an A+ rating marks an important development both in terms of the monocouche product range and as part of Weber’s sustainability credentials. The assessment undertaken by the BBA was very detailed and has enabled a deeper understanding of our processes, including highlighting areas for further environmental improvement.”

weber.floor level, a rapid-drying levelling compound for solid substrates such as cement/sand screeds and concrete, is self-smoothing and ideal for smoothing uneven floor surfaces. It can be laid up to 30mm deep and is suitable for foot traffic after only 2-4 hours. Once dry, it can be covered with tiles, carpet or wood.  

weber.floor flex, a rapid-drying, flexible, fibre-modified levelling compound is ideal for most substrates, including wood. This high performance compound is suitable for use with cement screeds, concrete slabs and pre-cast elements and is designed to work with under-floor heating, under-tile warming, wooden floors, including plywood and particle board panels, and can be applied over existing ceramic and rigid plastic tiles up to a bed thickness of 50mm.  

Priming with weber PR360 is required before application of both levellers to aid flow, maximise bond strength and reduce pin holes.  

“Both of these innovative compounds are ready for foot traffic in only 2 – 4 hours,” comments James Mead, Product Manager, Weber Flooring, “which contributes significantly to fast application and on-site efficiencies.  These two products have been designed to be easy to use whilst maintaining superior performance.”  

“These really are the next generation of easy to use, totally reliable levelling compounds.”

weber.pral M 'chalk' sample

Designed by McCarthy O’Hora Architects and built by P.Elliott Construction, the weber.therm external wall insulation system was installed by experienced applicator Denis O’Grady Builders of Limerick. Over 9,000m² of weber.therm EWI was applied to the concrete substrate during the eight months on-site programme. “The school build schedule was very tight and handover had to take place at the end of July without fail to enable the new school year to start in September. The weber.therm EWI system is so precise we can control progress very accurately and always meet exact timings,” reports Kevin O’Grady, Operations Director. The weber.therm EWI system has full IAB approval for all architectural applications in Ireland.  

For this modern school and sports hall facility at Naas, the O’Grady team used three advanced variants of the weber.therm EWI system. On ground floor walling the weber.therm XP system with weber.therm L1 mineral render finish was specified. This system comprises ferritic stainless steel lath mesh as the reinforcement for the through-coloured, one-coat, thick mineral render. The steel mesh gives extra durability against impact damage, particularly beneficial where bikes and footballs can be present. Higher walls feature the weber.therm XP system with weber.therm M1 mineral render finish where the lightweight meshcloth reinforcement is used. Further areas of the building’s walling have been finished with the weber.therm XM system. Pump application of the weber.rend PTS finish coat enabled an attractive hand scraped finish to be achieved. Selected wall panels were coated and coloured using weber.plast TF, an acrylic based composite decorative textured finish, which is factory batched for colour consistency and wet application.  

This attractive, modern school is designed to provide a pleasant and welcoming learning environment and the Weber insulation and walling systems ensure a healthy, comfortable and stylish construction.  

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Following the highly successful launch of Weber’s Mould Stop Technology, a manufacturing innovation applied to the original weber.joint wall grout in 2008, the company is rolling out this technological advance to other popular grout products including weber.joint fine flex, weber.joint wide and weber.joint wide flex.  

The Weber Mould Stop agent makes the surface of grout inhospitable to mould spores and unsightly fungus, and prevents its growth and spread.  “Householders are really pleased with the brighter, cleaner appearance this grout achieves,” says James Mead, Product Manager, Weber tile fixing.  “Maintenance is greatly reduced and hygienic areas look healthier and much more attractive.”  

Weber grouts with Mould Stop Technology are suitable for most interior and exterior locations including wet and moist areas such as kitchens, bathrooms, wet rooms, shower cubicles and swimming pools.  

Products in this Weber family of grouts are all cement-based and suitable for a range of applications and in a variety of colours.  

“Why spoil beautifully tiled rooms with ugly mould growth when professional tilers can now use a grout with all the benefits of Mould Stop Technology – these products are easy to use and give peace of mind to tilers and their customers,” says James Mead,  “The Mould Stop agent is a great example of Weber’s commitment to using only the best materials together with the latest technology in the manufacture of our products – and quite importantly, Weber has absorbed the additional cost of improving this product and bringing it to market.”  

These products come in a variety of package sizes and are delivered in shelf-ready and newly branded display packages for smart and tidy storage.

The high performance Weber External Wall Insulation (EWI) system has been used extensively in the landmark, riverside development of Clancy Quay, Dublin.  The scheme is built on the 5.5-hectare site of the former Clancy Barracks and residential units are incorporated within the refurbished Victorian buildings. The total 92,000-m² area comprises residential homes and a comprehensive selection of facilities including a hotel, religious centres, restaurants, bars, and recreational facilities within the re-instated 19th century central square.  

Over 730 residential units, from one bedroom apartments to smart town houses arranged in blocks of up to seven storeys, is the work of main contractor P Elliot & Co Ltd., Dublin and HKR Architects, Dublin. The architects specified the weber.therm EWI system and experienced applicator, Dennis O’Grady Builders of Limerick carried out the contract.  

Operations Director, Kevin O’Grady, reports that the project ran without a hitch. “We have used the weber.therm EWI system before. For Clancy Quay we had 10,000m² in all to complete during the 12-month build programme. We are always able to rely on the on-time deliveries from Weber’s local production plant so we can run a tight schedule on site. We installed the external wall insulation system onto concrete substrate and the weber.therm XM system is fast to apply and gives a great finish. Mushroom and silver finish colours were chosen and that really sets off the stylish aesthetics that has turned the old barracks into a much sought after residential location while significantly increasing the thermal performance of the buildings.”  

The weber.therm XM lightweight external wall insulation system incorporates meshcloth reinforcement with either a polymer basecoat LAC with a PTS scraped finish or LAC Basecoat with PTC and synthetic finish. This system offers a range of colour and texture finishes to enable the creation of striking visual finishes such as those used at Clancy Quay. The weber.therm system has full IAB approval.

Weber, leaders in the manufacture of external renders, external wall insulation (EWI) systems, construction mortars and tile fixing products, introduces a new Flooring Systems handbook following the successful acquisition of the Maxit Group from Heidelberg Cement.  

This comprehensive 16 page guide introduces the main product categories of commercial, industrial, decorative, calcium sulphate and marine screeds as well as innovative products such as Leca Insulation Fill for quick and easy foundation preparation.  

In all categories, weber.floor products have been developed for optimum speed of application allowing access by other trades in the shortest possible time.  High performance materials ensure strength and durability in the most demanding industrial applications while decorative screeds opens a new design concept for architects, designers and specifiers with striking, durable and low maintenance coloured floor finishes.  

Weber levelling compounds and screeds are the most technically advanced on the market providing consistent, reliable drying characteristics and optimum durability that can be applied directly onto concrete, as floating bonded or unbonded screed including acoustic, insulated or heated floors.   

“Weber doesn’t simply manufacture construction materials, we provide complete systems and problem solving flooring solutions,” says James Mead, Weber Product Manager, Flooring, ”and this includes substantial technical support and training to meet the professional needs of our customers – before, during and after contract periods.”

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U-values slashed from 2.1W/m2k down to 0.27  

In 1950 when the 80 prefabricated steel shell bungalows were assembled on Welland Close, Peterborough to house evacuated Londoners after the war, they would most certainly have been labelled ‘temporary’. However nearly sixty years later a major refurbishment project is underway to bring these quite spacious homes closer to today’s standard of thermal performance. A key factor in this plan is the use of the weber.therm XM external wall insulation (EWI) system.  

The walls of these bungalows are made from corrugated steel sheeting, the shape of the corrugations similar in pattern to today’s steel cladding systems used for industrial buildings. No insulation was provided other than the plaster board lining for the room interiors. In winter the steel is ice cold and in summer heat radiates off the metal internally making this one of the most uncomfortable construction methods ever!  

The properties are managed by Cross Keys Homes, the housing association created to take over Peterborough Council’s housing stock in 2000. In addition to the steel shell bungalows nearly 600 homes are undergoing improvements in a multi-million pound project that has benefited from £1 million worth of support secured by Weber from the CERT funding initiative. Main contractor Mears has renewed roofs, windows and doors whilst specialist applicator Retrofit is handling the £3.73 million weber.therm external wall insulation (EWI) system installation.  

The walling corrugations are first filled with polystyrene sheets to present a flat surface for the 80mm of high-density phenolic insulation, which is fixed by power drive screws to the crowns of the corrugated steel. The insulation is then covered by an initial coat of weber.rend LAC which is a low density, polymer-modified, dry powder, cement-based mortar with high bonding strength. This first coat of 3mm acts as the base for the lay-in of the mesh cloth that adds strength and stability to the render system. As the initial scrim goes “tacky” holding the mesh, the second coat of weber.rend LAC is applied to sandwich the mesh in 6mm of basecoat. weber.rend LAC is fast, economical and gives a smooth finish coat, ideal as the base for the weber.sil TF150 through-coloured decorative finish used here.  

The basecoat is primed with a roller application of weber PR310, a low viscosity, general purpose pigmented primer which effectively reduces surface suction and gives an appropriate colour wash prior to the application of the Weber finish render. This primer also contributes to the minimum 10-year life span of the coatings.  

The finish coat of weber.sil TF150 is a silicone based, through-coloured, decorative finish that is highly weather resistant, UV stable and produces a vapour permeable facade. weber.sil TF has an even textured finish using 1.5mm aggregate content. Cross Keys have offered residents a pallet of six colour choices. The weber.sil TF product is factory batched to ensure colour continuity. “The weber.therm system has really allowed us to push on rapidly with this project,” says Mick Wesley, project manager for Retrofit. “I have three men putting on the boarding and the speed of completing each unit has enabled me to get extra labour on site for the render applications so I am very confident we will keep ahead of the schedule. It’s great to see these properties at last getting some decent insulation. I know the residents are pleased.”  

The dramatic changes to the aesthetics of these Peterborough homes are matched by the changes in performance. “It’s much quieter inside now, we don’t hear so much traffic noise and it’s much warmer at night. We have to open the windows during warm summer nights so we will be saving a fortune on heating costs this winter,” reports Russell Ferguson who has lived in Welland Close for 16 years. He is also very pleased with the Mint Green colour finish, which he says, fits nicely with his well-maintained garden.  

In the Paston area of the City, Cross Keys Homes are improving additional homes built using the “no fines” precast panel system, which was then pebble-dashed. Here again the weber.therm external wall insulation (EWI) system is employed to add insulation and weatherproof render. Two-storey terrace houses and three storey town houses are being brought up to today’s thermal standards.  

Retofit is also using Weber’s brick slip finish system, weber.therm XB, on some 200 homes starting in Muswell Road, Peterborough. This was chosen by Cross Keys Homes as a cost effective way of producing a facade that replicates real brick work. This has been applied to 80mm phenolic foam.  

CERT (Carbon Emission Reduction Target) funding is the OFGEM managed Government programme that requires energy providers to encourage home owners to reduce their individual carbon emissions by providing funding assistance to energy saving action such as cavity wall and loft insulation, boiler upgrades and other heat loss measures. On the large scale of homes owned by a Housing Association the total funding that can be secured is substantial.

Cross Keys Homes has a rolling upgrade programme for its properties and with further funds now available an additional 150 units are receiving substantial thermal improvement. This additional capacity requirement is being met by experienced application contractor Lawtec Limited.  

The finish chosen for some of these properties uses the weber.rend RB system to produce a brick-effect finish to the EWI system.  The weber.rend RBB base, or “mortar joint” render, which is available in 8 colours, is applied first and allowed to set. Then the weber.rend RBF face, or “brick” render, is carefully applied. When the face layer has formed a skin, the brickwork pattern is cut through to face layer to expose the base layer to pattern. The weber.rend RB cutter is best used for this intricate job.  

weber.rend RB brick finish is being applied to a quantity of these homes to add another positive factor to the residents’ pleasure of a warm, quiet home.

 

weber.therm XM is a high performance external wall insulation (EWI) system suitable for a variety of insulation types and protected by mesh cloth-reinforced polymer modified renders. The lightweight system is BBA approved and provides efficient thermal insulation for both refurbishment and new build construction. A comprehensive range of colours and textures are available as a finish to the system to give buildings striking visual appeal.  

weber.therm XM is used extensively on solid wall (ie non-cavity) and non-traditional constructed housing and refurbishment of this kind is often suitable for grant assistance through energy supplier schemes. Contact Weber for further information (www.netweber.co.uk).  

“This adhesive reduces airborne dust during the preparation processes,” says James Mead, Weber Product Manager, “and will create a cleaner working environment.  It will prove particularly popular in homes where residents are present.”  

weber.set rapid SPF is a rapid setting, flexible cement-based floor and wall tile adhesive suitable for interior and exterior use.  It can be used to fix ceramic, porcelain and natural stone floor and wall tiles and is perfectly suited to underfloor heating applications and on wooden floors that have been over-boarded with 9mm WBP plywood or similar.  

weber.set rapid SPF with Low Dust Technology is ready for light foot traffic and grouting after only two hours and is available in both light grey and white 20kg bags.  

More product and technical information is available on tel: 01525 722169, or visit www.netweber.co.uk for a copy of the Weber Tiling Solutions handbook – a technical manual and product guide with problem solving situations and complete case studies – which is available in hard copy or CD format.  

Weber is the leading manufacturer of materials for the tile fixing, facade, construction mortars and flooring systems markets.  

weber.therm XP provides an attractive and thermally efficient answer to solid wall housing refurbishment and has contributed significantly to the overall success of this project – around 40% of the properties in this area are currently being refurbished with the system.  

Thermal efficiency is greatly improved for those properties that are being refurbished with weber.therm XP.  Phenolic insulation boards of 60mm thickness are fitted onto the original brick external walls and with the mesh cloth bonded into the external render for added strength, dramatic u-value improvements have been obtained. The existing construction gave a u-value of 2.90W/m2K but following the application of weber.therm XP this was slashed to a u-value of 0.32Wm2K, a remarkable and welcome reduction of heat loss for the residents.  

“The speed and versatility of the weber.therm XP system over traditional  multi-coat systems helps us keep this busy programme ahead of schedule and contributes substantially to the efficiency of the overall project,“ says Phillip Bristow, Housing Renewal Officer for EYRC.  Unlike traditional multi-coat systems Weber’s expertise in mineral renders has resulted in a one-coat, through-coloured mineral render which can be applied directly to all major insulation types.    

The mineral, through-coloured, one-coat render finishes available with weber.therm XP are contributing to the visual enhancement of the area, to the delight of the householders. Residents are given a choice from a palette of five pastel colours, a selection which sit happily together in terraced properties. The added attraction of these through coloured renders is that they are low maintenance requiring little or no cleaning over time.  

Mrs Violet Teale has lived in Cecil Street for more than 40 years and is delighted with the new aspects of her home. ”My first choice of colour was the blue, it’s my namesake really! Already I can feel that the house is warmer and I feel more secure too.”  

The Goole “Changing Streets” scheme is a housing regeneration project launched to fund badly needed improvements to 53 complete streets of over 2000 pre-1919 solid wall, private sector terraced homes. Improvements include the use of Weber external wall insulation systems; replacement windows and doors; new fascia and guttering and new boundary walls and railings.  

A pilot scheme of more than 100 properties on four streets determined that the weber.therm XP system would be used for the regeneration project. The benefits of the system were demonstrated early in this extensive project when the application contractor, Ray Clough of Lloyd Clough & Sons, offered to renovate the well-regarded local charity shop originated by the late Olive Hunt, MBE, which has raised over £500,000 for local causes. It was with the charity shop that Ray Clough was able to demonstrate the speed of application of the weber.therm XP system following the pilot scheme in which an alternative traditional multi-coat render proved substantially slower in application and drying capability.  

“The speed at which we can install the weber.therm XP has significant impact on the reduction of on-site hours and other factors, such as the cost of scaffolding hire on site,” continues Ray.  Being a one-coat system there is no waiting for a base coat to dry and the material can be applied by machine pump making the application the most economical in the industry.  “And being able to minimise disruption to tenants is a prime consideration,” says Ray  

The entire project has been an excellent example of real “partnership” co-operation led by the Housing Renewal Team of East Riding of Yorkshire Council, Interserve Project Services, one of the Council’s main framework contractor and a group of specialist building service contractors who formed a close-knit partnership with a strong “can do” ethic. Equally, close communication has been maintained with all residents and, additionally, commercial premises owners in the target streets. Consultation meetings, project displays and resident briefings have resulted in a 99% take-up of the plan.                

Simon Woods has been managing the project team and praises the supplier partnership that has matured quickly to undertake greater numbers of renovations. “The weber.therm XP system takes just three days per property, one to board out the insulation, one to render and one to scrape back the finish. It enables me to move the schedule capacity up to meet the Council’s expectations.”  

Phillip Bristow, Housing Renewal Officer for ERYC, comments that resident reaction is very, very positive: “Everyone is very happy with the render appearance and choice of colours and the instantaneous improvement in warmth provided by the insulation is music to our ears.”  

So strong have been the results that further funding from the Regional Housing Board and the Humber Partnership Group has been agreed and the programme advanced to cover more homes.  450 properties will have been refurbished during 2008-09. It is projected that half of the 53 streets identified may well be completed ahead of the 2011 schedule.  

Weber’s range of services includes not only full technical advice and support but also assistance in securing funding for solid wall insulation schemes through either the current CERT programme or the forthcoming CESP initiative targeted at low income communities with a high concentration of ‘hard-to-treat’ homes.